Cable Reinforcement via Flexible Wire Wrapping and Soldering
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Solution Overview
Problem
Cables used in high frequency, radio frequency, and microwave applications are prone to fatigue, fracturing, and breakage due to shock, vibration, and heat-based connection techniques, leading to reliability issues in extreme environments.
Innovation Solution
A method involving wrapping a flexible wire around the external surface of a cable and soldering it to reinforce the cable, particularly between the cable and a connector, to enhance its resistance to stress and breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat-based connection techniques (soldering, brazing, welding) are used to couple cables, then connection strength is improved, but cable fatigue and fracturing increase due to heat exposure and subsequent environmental stress
Solution Approach 1:
The cable is wrapped with a reinforcement tube before the heat-based connection process. This preliminary protective action prevents the cable from suffering fatigue and fracturing during subsequent soldering, brazing, or welding operations and under later environmental stress, while still allowing strong connections to be made.
2Adaptability or versatility
If cables are subjected to shock and vibration in operating environments, then operational capability is maintained, but cable fracturing and breakage increase
Solution Approach 1:
The cable is wrapped with a reinforcement tube before deployment in shock and vibration environments. This beforehand protective measure cushions the cable against mechanical stress, preventing fracturing and breakage while maintaining full operational capability in demanding environments.
3Reliability
If reinforcement is applied to cables, then cable durability is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
A flexible reinforcement tube is used to wrap the cable. This thin-walled protective structure provides durable protection against fatigue, fracturing, and breakage without significantly increasing device complexity. The flexible nature of the tube allows it to conform to the cable while providing strength, and the wrapping process integrates easily into existing manufacturing workflows.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The reinforcement method significantly reduces the likelihood of cable breakage and fatigue, ensuring the cable's integrity under various environmental and physical stresses, including high-temperature and ultraviolet exposure, in a cost-effective manner.
Implementation Method 1
soldering the flexible wire to the cable, thereby positioning the flexible wire with respect to the cable
Data Source
AI summary
A method and apparatus of reinforcing a cable includes wrapping a flexible wire around at least a portion of an external surface of the cable, and soldering the flexible wire to the cable, thereby positioning the flexible wire with respect to the cable. The portion of the external surface of the cable wrapped with the flexible wire may be disposed between the cable and a connector, or represent an entire length of the cable. Wrapping the flexible wire may involve wrapping the flexible wire around a portion of the external surface of the cable such that coils of the flexible wire are disposed apart from each other, and sliding the coils together such that the coils of the flexible wire are touching each other.